Manual MP3 400

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SERVICE STATION MANUAL

664502(IT)-664503(EN)-664504(FR)-664505(DE)-664506(ES)-664507(PT)-664508(NL)-664509(EL)

MP3 400 i.e.

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SERVICE STATIONMANUAL

MP3 400 i.e.

The descriptions and illustrations given in this publication are not binding. While the basic specificationsas described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at

any time and without being required to update this publication beforehand, to make any changes tocomponents, parts or accessories, which it considers necessary to improve the product or which are

required for manufacturing or construction reasons.Not all versions/models shown in this publication are available in all countries. The availability of single

versions should be checked at the official Piaggio sales network." Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication

in whole or in part is prohibited.PIAGGIO & C. S.p.A. - After-Sales

V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

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SERVICE STATION MANUALMP3 400 i.e.

This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops ofPiaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggiovehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Anysignificant changes to vehicle characteristics or to specific repair operations will be communicated byupdates to this manual. Nevertheless, no mounting work can be satisfactory if the necessary equipmentand tools are unavailable. It is therefore advisable to read the sections of this manual concerning specialtools, along with the special tool catalogue.

N.B. Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personalinjury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicleto prevent damaging the environment.

Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of seriousdamage to the vehicle and sometimes even the invalidity of the guarantee.

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INDEX OF TOPICS

CHARACTERISTICS CHAR

TOOLING TOOL

MAINTENANCE MAIN

TROUBLESHOOTING TROUBL

ELECTRICALSYSTEM ELE SYS

ENGINEFROMVEHICLE ENG VE

ENGINE ENG

INJECTION INJEC

SUSPENSIONS SUSP

BRAKINGSYSTEM BRAK SYS

COOLINGSYSTEM COOL SYS

CHASSIS CHAS

PRE-DELIVERY PRE DE

TIME TIME

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INDEX OF TOPICS

CHARACTERISTICS CHAR

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This section describes the general specifications of the vehicle.

Rules

This section describes general safety rules for any maintenance operations performed on the vehicle.

Safety rules

- If work can only be done on the vehicle with the engine running, make sure that the premises are well-

ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust

fumes are toxic.

- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is

highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant waterand seek immediate medical attention.

- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks

or flames near the battery, especially when charging it.

- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working

area, and avoid naked flames or sparks.

- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that

you do not breathe in the dust produced by the wear of the friction material. Even though the latter

contains no asbestos, inhaling dust is harmful.

Maintenance rules

- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or

non-conforming spare parts may damage the vehicle.

- Use only the appropriate tools designed for this vehicle.

- Always use new gaskets, sealing rings and split pins upon refitting.

- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all

the work surfaces, except tapered couplings, before refitting these parts.- After refitting, make sure that all the components have been installed correctly and work properly.

- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and

screws are not interchangeable with coupling members with English measurement. Using unsuitable

coupling members and tools may damage the scooter.

- When carrying out maintenance operations on the vehicle that involve the electrical system, make

sure the electric connections have been made properly, particularly the ground and battery connections.

MP3 400 i.e. Characteristics

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Vehicle identification

Chassis prefix (A):

ZAPM59101 (MP3 400 i.e. version)

ZAPM59102 (MP3 400 i.e. RL version)

Engine prefix (B):

M474M

Dimensions and mass

MP3 400 i.e.

WEIGHTS AND DIMENSIONSSpecification Desc./Quantity

Kerb weight 253 5 kg

Maximum weight allowed 445 kg

Maximum height 1.225 mm

Width 745 mm

Wheelbase 1.550 mm

Length 2.180 mm

Track 420 mm

Characteristics MP3 400 i.e.

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MP3 400 i.e. RL

WEIGHTS AND DIMENSIONSSpecification Desc./Quantity

Kerb weight 253 5 kgMaximum weight allowed 445 kg

Maximum height 1.225 mm

Width 745 mm

Wheelbase 1.550 mm

Length 2.180 mm

Track 425 mm


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Engine

ENGINESpecification Desc./Quantity

Type Single-cylinder, 4-stroke

Cubic capacity 399 cm

Bore x stroke 85.8 X 69 mm

Compression ratio 10.6 0.5 : 1

Engine idle speed 1,500 100 rpm

Timing system Four valves, single overhead camshaft, chain-driven.

Valve clearance Inlet: 0.15 mmOutlet: 0.15 mm

MAX Power 24 kW at 7,250 rpmMAX torque 38 Nm at 5,250 rpm

LUBRICATION Engine lubrication with trochoidal pump (inside the crankcase),oil filter and pressure adjustment by-pass.

Lubrication pressure 3.5 4 bar

Minimum lubrication pressure (100C) 0.8 bar

Fuel supply Electronic injection with 38-mm throttle body and electric fuelpump.

Cooling Forced coolant circulation system.

Fuel Unleaded petrol (95 RON)


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Transmission

TRANSMISSIONSpecification Desc./Quantity

TRANSMISSION Automatic expandable pulley variator with torque server, V-belt, automatic clutch.

Final reduction Gear reduction unit in oil bath.

Capacities

CAPACITYSpecification Desc./Quantity

Engine oil 1.7 l

Transmission oil 250 cm

Cooling system fluid ~ 1.8 l

Fuel tank (reserve) approx. 12 l (approx. 2 l)

Electrical system

ELECTRICAL SYSTEMSpecification Desc./Quantity

Start-up Electric

Ignition Electronic, inductive, high efficiency ignition, integrated with theinjection system, with variable advance and separate HV coil.

Ignition advance Three-dimensional map managed by control unit

Spark plug (MP3 400 i.e.) CHAMPION RG 6 YC

Alternative spark plug (MP3 400 i.e.) NGK CR7EKB

Spark plug (MP3 400 i.e. RL) CHAMPION RG 6 Y

Battery 12V/14 Ah, sealed battery

Generator Alternating current

Frame and suspensions

CHASSIS AND SUSPENSIONS

Specification Desc./Quantity

Chassis Tubular and sheet steel

Front suspension The tilt mechanism is composed of an articulated parallelogramsuspension with die-cast aluminium control arms and two side

headstocks plus shock absorbers with hydraulic locking sys-tem.

Front suspension travel 85 mm

Rear suspension Two double-acting shock absorbers, adjustable to four posi-tions at preloading.

Rear suspension travel 110 mm

Brakes

BRAKES


Front brake 240 mm double disc brake with hydraulic control activated

by the handlebar right-hand lever.Rear brake 240 mm disc brake, with hydraulic control activated by thehandlebar left-hand lever.


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Wheels and tyres

WHEELS AND TYRESSpecification Desc./QuantityWheel rim type Light alloy rims.

Front rim 12'' x 3.00

Rear rim 14'' x 4.50

Front tyre Tubeless, 120/70-12" 51S or 51P

Rear tyre (MP3 400 i.e.) Tubeless 140/70 -14" 68S or 68P reinf.

Rear tyre (MP3 400 i.e. RL) Tubeless, 140/70 -14" 68S or 68P

Front tyre pressure with passenger (MP3 400 i.e.) 1.6 bar (1.8 bar)

Rear tyre pressure with passenger (MP3 400 i.e.) 2.4 bar (2.6 bar)

Front tyre pressure (MP3 400 i.e. RL) 1.6 bar

Rear tyre pressure (MP3 400 i.e. RL) 2.5 bar

Tightening Torques

STEERINGName Torque in Nm

Steering lower ring nut (central headstock) 22 27 loosen by 90

Steering upper ring nut (central headstock) 27 33

Handlebar fixing screw 50 55

Fixing screws for the handlebar control unit U-bolts 7 10

CHASSISName Torque in Nm

Swinging arm set screw bushing 5 7

Engine arm bolt - frame arm 32.5 40

Swinging arm set screw bushing nut 54 60Engine-swinging arm bolt 98 118

Frame-swinging arm bolt 54 60

Centre stand bolt 31 39

FRONT SUSPENSIONName Torque in Nm

Lower shock absorber clamp 19 26

Upper shock absorber clamp 19 29

Front wheel fixing screws 19 24

Steering arm bolt nut 20 25

Tilt gripper fixing screws 20 25

Front wheel axle 74 88

Arm coupling screws 45 50

Screws fixing arms to side headstocks 45 50Screws fixing arms to central headstock 45 50

Screws fixing the half-arm coupling flange 20 25

Screws fixing tilt locking disc section 20 25

Side headstock upper ring nut 20 24

Side headstock lower ring nut 12 15

Screw fixing sliding stem to shock absorber 45 50

Clamp for sliding stem locking device 6.5 10.5

Fixing nuts for constant-velocity universal joints 18 20

Potentiometer to anti-tilting device clamp 8 10

Electric motor to anti-tilting device clamp 11 13

Clamp fixing pump bolt to anti-tilting device 11 13

Pump to anti-tilting device clamp 11 13

Pressure switch to distribution frame 18 20

Sensor to tilt gripper clamp 2.5 2.9

Pipe terminals to fifth wheel check spring 7 11Joint to anti-tilting device pump 20 25

Lower fitting for shock absorber sliding locking clamp pipes 20 25


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Name Torque in Nm

Upper fitting for shock absorber sliding locking clamp pipes 20 25

REAR SUSPENSIONName Torque in Nm

Upper shock absorber clamp 33 41Lower shock absorber clamp 33 41

Shock absorber-crankcase attachment bracket 20 25

Rear wheel axle 104 126

Muffler arm clamping screws 27 30

FRONT BRAKEName Torque in Nm

Calliper coupling screw 22 27

Oil bleed screw 8 12

Disc tightening screw () 5 6

Brake fluid pump-hose fitting 16 20

Brake fluid pipe-calliper fitting 20 25

Screw tightening calliper to support 20 25

Calliper upper pipe fitting 20 25

REAR BRAKEName Torque in Nm

Oil bleed screw 1216

Rear brake disc screws() 5 6.5

Rear brake calliper-pipe fitting 20 25

Rigid / flexible pipe fitting 13 18

Rear brake pump-pipe fitting 16 20

Rear brake calliper fixing screws 20 25

pad fastening pin screws 20 25

REAR BRAKE

Product Description Specifications() Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium-strength

threadlock

MUFFLERName Torque in Nm

Muffler heat guard fixing screw 4 5

Screw for fixing muffler to the support arm 20 25

Lambda probe tightening on exhaust manifold 40 50

Exhaust manifold-muffler joint tightening 1213

Manifold - muffler diaphragm tightening clamp 16 18

LUBRICATION

Name Torque in NmOil pump cover screws 0.7 0.9

Screws fixing oil pump to the crankcase 5 6

THERMAL GROUP AND TIMING SYSTEMName Torque in Nm

Spark plug 12 14

Head fixing stud bolts ***

Head fixing nuts 10 - 12

Exhaust / intake head fixing nuts 10 - 12

Head lubrication control jet 5 - 7

Coolant temperature sensor: 10 - 12

Lambda probe on exhaust manifold 10 - 12

injector fixing screw 3 4

Counterweight screw 7 8.5Tensioner sliding block fixing screw 10 - 14

Rpm timing sensor fixing screw 3 - 4


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Name Torque in Nm

Valve lifter mass stop bell fixing screws 30 - 35

Inlet manifold screws 11 13

Tappet cover fixing screws 7 - 9

Throttle body fixing screws 11 13

Head fixing screws 10 - 12

Camshaft retaining bracket screws: 4 6Tightener screw: 5 6

Tightener fastening screws: 11 13

*** Apply a preliminary torque of 7 Nm in a crossed sequence. - Tighten by 90in a crossed sequence. - tighten again by 90ina criss-crossed sequence.

TRANSMISSION COVERName Torque in Nm

Driven pulley nut 92 - 100

Drive pulley nut 160 - 175

Anti-vibration roller screw 16.7 19.6

M8 retainers for transmission cover 23 26

M6 retainer 11 13

Anti-vibration roller retainer 17 - 19

Clutch ring nut 65 - 75

Air conveyor screws 11 12

Water pump cover screws 3 4

External transmission cover screws 7 9

Flywheel cover screws 11 - 13

FLYWHEEL COVERName Torque in Nm

Chain guide sliding block retain plate fastening screws 3 4

Flywheel fixing nut 115 - 125

Stator retainers 8 - 10

Blow-by recovery duct fixing screws 3 - 4

Screw fixing freewheel to flywheel 13 15

Stator cable harness guide bracket screws 3 - 4

Supporting screws with bulkhead 0.3 - 0.4

Minimum oil pressure sensor 12 14

Water pump impeller 4 5

CRANKCASE AND CRANKSHAFT

Name Torque in Nm

Countershaft fixing nut 25 29

Engine oil filter 12 - 16

Engine oil drainage plug 24 30

Engine-crankcase coupling screws 11 13

Oil pump screws 5 6

Gear mounting on crankshaft screws 10 -12

Bulkhead screws for oil pump housing cover 8 - 10

COOLING

Name Torque in Nm

Water pump impeller 4 5

Water pump cover screws 3 4

Thermostat cover screws 3 4

Bleed screw 3

Overhaul data

Assembly clearances


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Cylinder - piston assy.

HEIGHT AT WHICH THE DIAMETER SHOULD BE MEASUREDSpecification Desc./Quantity

A 43.2 mm

B 43 mm

CYLINDER- PISTON


Cylinder diameter C 85.8 - +0.018 -0.01 mm

Piston P 85.768 0.014 mm

CYLINDER - PISTON

COUPLING CATEGORIESName Initials Cylinder Piston Play on fitting

Cylinder- Piston A 85.79085.797 85.75485.761 0.0290.043

Cylinder- Piston B 85.79785.804 85.761 85.768 0.0290.043

Cylinder- Piston C 85.80485.811 85.76885.775 0.0290.043

Cylinder- Piston D 85.81185.818 85.77585.782 0.0290.043CATEGORIES OF COUPLING

N.B.

THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE EXHAUST SIDE,THE PISTON RINGS MUST BE INSTALLED WITH THE WORD TOP OR THE STAMPED MARKFACING UPWARDS.


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Piston rings

*Fit rings 2 and 3 with the word TOP facing upwards.

** Position the port of the rings as shown here.

***Value A of sealing ring inside the cylinder.

Check the size of the sealing ring opening:

Compression ring: 0.15 0.35 mm. Max. value 0.5 mm

Oil scraper ring: 0.25 0.50 mm. Max. value 0.65 mm

Oil scraper ring: 0.25 0.50 mm. Max. value 0.65 mm

Rings/housing coupling clearances:

Carefully clean the sealing ring housings.

Place a thickness gauge between the ring and the

housing as shown in the drawing and check the

coupling clearances.

Top ring Standard coupling clearance:

0.010.06 mm

Maximum clearances allowed after use: 0.10

mm

Intermediate ringStandard coupling clear-

ance:0.020.07 mm


mm


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Oil scraper ringStandard coupling clearance:

0.010.06 mm


mm

Replace the piston if clearances exceed the max-

imum limits specified in the table.

Crankcase - crankshaft - connecting rod

- Measure the diameter of bushings A in the

three directions shown in the figure.

- Measure the diameter of the crankshaft bearings

B.

- Check that the diametral clearance A-B is be-

tween the pre-set interval.

Characteristic

Diameter clearance

0.025 0.043 mm

If value A-B is above the limit, check that value B is within the admissible values of the categories.

CRANKSHAFT


Category 1 40.02040.026Category 2 40.02640.032

If the crankshaft is within the set limits, replace the crankshaft half-bearings mounting the crankcase

so as to suit the specified couplings. The crankcase halves can be mounted with four types of crankshaft

half-bearings identified by letters A (red), B (blue), C (yellow), D (green).

CRANKCASESpecification Desc./Quantity

Category 1 43.974 43.980

Category 2 43.980 43.986

Category 3 43.986 43.992


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CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGSSpecification Desc./Quantity

Crankshaft category 1 - Crankcase category 1 B+B, A+C

Crankshaft category 2 - Crankcase category 1 A+A

Crankshaft category 1 - Crankcase category 2 C+C, B+DCrankshaft category 2 - Crankcase category 2 B+B, A+C

Crankshaft category 1 - Crankcase category 3 D+D

Crankshaft category 2 - Crankcase category 3 C+C, B+D

Characteristic

crankshaft / crankcase axial clearance:

0.1 0.405 mm

Diameter of crankshaft bearings.

Measure the bearings on both axes x-y.

CRANKSHAFTSpecification Desc./Quantity

Cat. 1 Standard diameter: 40.02040.026Cat. 2 Standard diameter: 40.02640.032

Crankshaft alignment

Specific tooling

020335YMagnetic support for dial gauge


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MAX. ADMISSIBLE DISPLACEMENTSpecification Desc./Quantity

A = 0.15 mm

B = 0.010 mm

C = 0.010 mmD = 0.10 mm

AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD

Name Description Dimensions Initials Quantity

Transmission-sideshoulder

10.025 A D = 0.20 - 0.50

Half-shaft, transmissionside

20.9 -0.05 B D = 0.20 - 0.50

Connecting rod 22 -0.10 -0.15 C D = 0.20 - 0.50

Flywheel-side shoulder 1.80.025 F D = 0.20 - 0.50

Flywheel-side half-shaft 19.6 -0.05 E D = 0.20 - 0.50

Complete crankshaft 65.5 +0.10 -0.05 G D = 0.20 - 0.50

Slot packing system

Shimming system for keeping the compression ra-

tioDISTANCE A IS A PROTRUSION OR RECESS VALUE OFTHE PISTON CROWN WITH RESPECT TO THE CYLINDERPLANE.DISTANCE A HELPS DETERMINE THE THICKNESS OFGASKET B THAT HAS TO BE FITTED TO THE CYLINDERHEAD IN ORDER TO RESTORE COMPRESSION RATIO.BASE GASKET B MUST BE THICKER THE MORE THEPLANE FORMED BY THE PISTON TOP PROTRUDESFROM THE PLANE FORMED BY THE CYLINDER HEAD. ONTHE OTHER HAND, THE MORE THE PISTON TOP IS RE-CESSED INTO THE CYLINDER TOP PLANE, THE SMALL-ER THE GASKET THICKNESS.

Characteristic

Compression ratio


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10.6 0.5 : 1

BASE GASKET THICKNESSName Measure A Thickness

A MEASURE TAKEN - 0.185 - - 0.10 0.4 0.05A MEASURE TAKEN - 0.10 - + 0.10 0.6 0.05

A MEASURE TAKEN + 0.10 + 0.185 0.8 0.05

N.B.

VALUES INDICATED WITH - REFER TO PISTON CROWN RECESSES WITH RESPECT TO THECYLINDER PLANE.

N.B.

DISTANCE A MUST BE MEASURED WITHOUT ANY GASKET FITTED AT B

Products

RECOMMENDED PRODUCTS TABLEProduct Description Specifications

AGIP GEAR 80W-90 Oil for speed gearbox SAE 80W-90, API GL-4 mineral multi-grade oil

AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions(throttle control)

Oil for 4-stroke engines

AGIP GP 330 Grease for brake levers, throttle White calcium complex soap-basedspray grease with NLGI 2; ISO-L-XBCIB2

AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MASynthetic oil

AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid

SPECIAL AGIP PERMANENT fluid coolant Monoethylene glycol-based antifreezefluid, CUNA NC 956-16

AUTOSOL METAL POLISH Muffler cleaning paste special product for cleaning and polishingstainless steel muffler

AGIP GREASE PV2 Grease for steering bearings, pin seatsand swinging arm

Soap-based lithium and zinc oxidegrease containing NLGI 2; ISO-L-

XBCIB2 of the swinging arm


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INDEX OF TOPICS

TOOLING TOOL

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SPECIFIC TOOLSStores code Description

001330Y Tool for fitting steering seats

001467Y002 Driver for OD 73 mm bearing

001467Y006 Pliers to extract 20 mm bearings

001467Y007 Driver for OD 54-mm bearings

001467Y008 Pliers to extract 17 mm bearings

001467Y014 Pliers to extract 15-mm bearings

Tooling MP3 400 i.e.

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Stores code Description

001467Y031 Bell

001467Y034 Pliers to extract 15-mm bearings

001467Y035 Bearing housing, outside 47 mm

002465Y Pliers for circlips

006029Y Punch for fitting fifth wheel seat on steer-ing tube

020004Y Punch for removing fifth wheels fromheadstock

MP3 400 i.e. Tooling

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020055Y Wrench for steering tube ring nut

020150Y Air heater support

020151Y Air heater

020193Y Oil pressure check gauge

020201Y Spacer bushing driving tube

020262Y Crankcase splitting plate

020306Y Punch for assembling valve seal rings


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020329Y Mity-Vac vacuum-operated pump

020330Y Stroboscopic light to check timing

020331Y Digital multimeter

020648Y Single battery charger

020335Y Magnetic support for dial gauge

020357Y 32x35-mm Adaptor



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020364Y 25-mm guide

020376Y Adaptor handle

020382Y012 bush (valve removing tool)

020412Y 15-mm guide

020424Y Driven pulley roller casing fitting punch


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020431Y Valve oil seal extractor

020434Y Oil pressure check fitting

020439Y 17-mm guide

020444Y Tool for fitting/ removing the driven pulleyclutch

020456Y 24 mm adaptor


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020458Y Puller for lower bearing on steering tube

020459Y Punch for fitting bearing on steering tube

020460Y Scooter diagnosis and tester

020467Y Flywheel extractor

020468Y Piston assembly band


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020469Y Reprogramming kit for scooter diagnostictester

020470Y Pin retainers installation tool

020471Y Pin for countershaft timing

020472Y Flywheel lock wrench

020474Y Driving pulley lock wrench


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020475Y Piston position checking tool

020476Y Stud bolt set

020478Y Punch for driven pulley roller casing

020479Y Countershaft lock wrench

020480Y Petrol pressure check set

020481Y Control unit interface wiring


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020482Y Engine support

020483Y 30-mm guide

020512Y Piston fitting fork

020527Y Engine support base

020604Y011 Fitting adapter

020565Y Flywheel lock calliper spanner

020640y software euro 3


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020481Y004 Parking control unit interface wiring

Marelli MIU diagnosis software Marelli MIU diagnosis software

020646Y Parallelogram and steering positioningtool

020647Y Toe-in checking tool

020661Y Water pump overall seal replacement kit


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INDEX OF TOPICS

MAINTENANCE MAIN

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Follow these steps to reset the service icons:

1. With the key set to OFF, hold down the

"SET" button and turn the key to ON : the

"BELT" and "SERVICE" icons start flashing.

2. Push the "CLOCK" button for less than 1

second and the icons are displayed sequen-

tially. The icon selected remains ON and the

other is no longer displayed.

3. Press the "CLOCK" button again for more

than 3 seconds to reset the relative mainte-

nance step and the icon is no longer dis-

played.

Maintenance chart

SCHEDULED MAINTENANCE TABLE

I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY.C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE* Replace every 2 years

km x 1,000 1 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Safety locks I I I I I

Throttle control A A A A A A A A AEngine oil filter R R R R R R R R R

Electrical system and battery I I I I I

Coolant level * I I I I I I I I I

Brake oil level* I I I I I I I I I

Engine oil R I R I R I R I R I R I R I R I R

Brake pads I I I I I I I I I I I I I I I I I

Tyre pressure and wear I I I I I I I I I

Vehicle and brake test - test ride I I I I I I I I I

Hub oil R I R R I R I R

Steering I I I I I I I I I

Parking control unit software upgrading(if available)

I I I I I I I I I I I I I I I I I

Centre stand L L L L L L L L L L L L L L L L

Driving belt R R R R R R R R

Air filter C I C I C I C ISliding blocks / variable speed rollers R R R R R R R R

Suspensions I I I I I I I I

Spark plugs R R R R R R R R

Tilt locking caliper control cable A A A A A A A A

Valve clearance I I I I

Electrical system and battery I I I

Maintenance MP3 400 i.e.

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Checking the spark advance

The ignition advance is determined electronically

on the basis of parameters known by the control

unit. For this reason it is not possible to interpret

the reference values based on the engine rpm.

The ignition advance value is detectable at any

time using the diagnostic tester. It is possible to

check whether the ignition advance determined by

the injection system matches the value actually

activated on the engine, by means of the strobo-

scopic light.

Proceed as follows:

- Remove the spark plug.

- Remove the transmission crankcase.

- Rotate the driving pulley fan until the reference

marks between the flywheel and flywheel cover

meet as shown in the photograph.

- Bring the reference mark onto the transmission

side between the fan and the transmission cover

as shown in the photograph.

- Refit the spark plug.

- Refit the plastic cap on the flywheel cover.

- Adjust the spark gap to the contact position (no

reference mark visible) and install it on the engine

between the spark plug and spark plug cap

- Connect the induction clamp on the spark gap

cable respecting the proper polarity (the arrow on

the clamp must be pointing at the spark plug).

MP3 400 i.e. Maintenance

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- Connect the diagnostic tester.

- Start the engine.

- Select the parameters function in this menu.

- Select the stroboscopic light control in the tradi-

tional four-stroke engine position (1 spark, 2 revs).

- Check that the real values of rpm and ignition

advance match those measured using the diag-

nostic tester.

If the values do not correspond, check:

- distribution timing

- revolution timing sensor

- injection control unit

Specific tooling

020460YScooter diagnosis and tester

020330YStroboscopic light to check timing

020621YHV cable extraction adaptor

Spark plug

Remove the port on the left-hand side panel of the

vehicle by undoing the fixing screw and using a

small screwdriver in the rear recess shown in the

figure, then do the following:

- Disconnect the HV wire cap A of the spark

plug;

- Unscrew the spark plug using the wrench sup-

plied;

- Upon refitting, place the spark plug at the re-

quired angle and tighten by hand until it is finger

tight;

- Use the wrench only for final tightening of the

spark plug;

- Place cap A fully over the spark plug.

- Refit the port making sure the rear hook is inser-

ted.

WARNING


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THE SPARK PLUG MUST BE REMOVED WHEN THE EN-GINE IS COLD. REPLACE THE SPARK PLUG AS INDICA-TED IN THE SCHEDULED MAINTENANCE TABLE. THEUSE OF ELECTRONIC CENTRAL UNITS AND OF NON-COMPLIANT ELECTRONIC IGNITIONS OR SPARK PLUGSOTHER THAN THOSE PRESCRIBED MAY SERIOUSLY

DAMAGE THE ENGINE.N.B.

USING SPARK PLUGS OTHER THAN THE INDICATEDTYPE OR SHIELDLESS SPARK PLUG CAPS CAN CAUSEELECTRICAL SYSTEM FAILURES.

Characteristic

Spark plug

CHAMPION RG 6 YC

Alternative spark plug

NGK CR7EKB

Electric characteristic

Electrode gap

0.7 0.8 mm

Hub oil

Check

-Park the vehicle on its centre stand on flat ground;

- Remove the oil dipstick A, dry it with a clean

cloth and put it back into its hole tightening it

completely;

Remove the dipstick and check that the oil level is

slightly over the second notch starting from the

lower end; if the level is below the MAX mark, it

needs to be filled up with the right amount of hub

oil.

-Screw up the oil dipstick again and make sure it

is locked properly into place.


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Replacement

-Remove the oil filler cap A.

- Unscrew the oil drainage cap B and drain out

all the oil.

- Screw in the drainage cap again and fill the hub

with the prescribed oil.

Recommended products

AGIP ROTRA 80W-90Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of

API GL3 specifications

Characteristic

Rear hub oil

Capacity approximately 250 cc

Air filter

Proceed as follows:

Unscrew the nine fixing screws A and remove

the air filter cover.

- Wash the sponge with water and mild soap.

- Dry it with a clean cloth and short blasts of compressed air.

- Soak it in a mixture of 50% petrol and 50% specified oil.

- Gently squeeze the filtering element with your hands but do not wring it; allow it to drip dry and then

refit.

CAUTION

IF THE VEHICLE IS USED ON DUSTY ROADS IT IS NECESSARY TO CARRY OUT MAINTENANCE

CONTROLS OF THE AIR FILTER MORE OFTEN TO AVOID DAMAGING THE ENGINE.



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AGIP FILTER OILOil for air filter sponge

Mineral oil with specific additives for increased adhesiveness

Engine oil

In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the

thermal group. An insufficient quantity of oil can cause serious damage to the engine.

In all 4T engines, the deterioration of the oil characteristics, or a certain consumption should be con-

sidered normal, especially if during the run-in period. Consumption levels in particular can be influenced

by the conditions of use (e.g.: oil consumption increases when driving at "full throttle".

Replacement

Change oil and replace filter as indicated in the

scheduled maintenance table. Empty the engine

by draining the oil through drainage plug B.

To facilitate oil drainage, loosen the cap/dipstick

A.

Once all the oil has drained through the drainage

hole, unscrew and remove the oil cartridge filter

C .


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Make sure the pre-filter and drainage plug O-rings

are in good conditions.

Lubricate them and refit the mesh filter and the oil

drainage plug, screwing them up to the prescribed

torque.

Refit the new cartridge filter being careful to lubri-

cate the O-ring before fitting it.

Change the engine oil.

Since a certain quantity of oil still remains in the

circuit, engine oil must be added through plug

A. Then start the scooter, leave it running for a

few minutes and switch it off: after five minutescheck the level and if necessary top up without

exceeding the MAX level. The cartridge filter must

be replaced every time the oil is changed. Use new

oil of the recommended type for topping up and

changing purposes.

N.B.

THE ENGINE MUST BE HOT WHEN THE OIL IS CHANGED.


AGIP CITY HI TEC 4TEngine oil

SAE 5W-40 Synthetic oil that exceed the require-

ments of API SL, ACEA A3, JASO MA specifica-

tions

Locking torques (N*m)

Engine oil filter12 - 16Engine oil drainage plug24 30

Check

This operation must be carried out with the engine

cold and following the procedure below:

- Place the vehicle on its centre stand and on flat

ground.

- Unscrew the cap/dipstick A, dry it with a clean

cloth and reinsert it, screwing it all the way

down.


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- Remove the cap/dipstick again and check that

the level is between the min and max reference

marks; top-up, if required.

If the check is carried out after the vehicle has

been used, and therefore with a hot engine, the

level line will be lower; in order to carry out a cor-

rect check, wait at least 10 minutes after the en-

gine has been stopped so as to get the correct

level.

Oil top up

The oil should be topped up after having checked

the level and in any case by adding oil withoutever exceeding the MAX. level.

Restoring the level from the MIN to the MAX marks

requires approx. 400 m of oil.

Engine oil filter

The cartridge filter must be replaced every time the oil is changed. Use new oil of the recommended

type for topping up and changing purposes.

Make sure the pre-filter and drainage plug O-rings are in good conditions. Lubricate them and refit the

mesh filter and the oil drainage plug, screwing them up to the prescribed torque. Refit the new cartridge

filter being careful to lubricate the O-ring before fitting it. Change the engine oil.


AGIP CITY HI TEC 4TEngine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications


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Oil pressure warning light

The vehicle is equipped with a warning light on the

instrument panel that lights up when the key is

turned to the ON position. However, this light

should switch off once the engine has been star-

ted.

If the light turns on during braking, at idling

speed or while turning a corner, it is necessary

to check the oil level and the lubrication sys-

tem.

Checking the ignition timing

- Remove the plastic cap on the flywheel cover

-Turn the flywheel until the reference mark T on

the rotor matches the reference mark on the fly-

wheel cover as shown in the figure (TDC). Make

sure that the 4V reference point on the camshaft

control pulley is aligned with the reference point on

the head as shown in the second figure. If the ref-

erence is opposite the indicator on the head, turn

the crankshaft once more.

For the use of this reference mark, remove the

spark plug and turn the engine in the direction that

is the reverse of the normal direction using a cal-

liper spanner applied to the camshaft command

pulley casing.

Cooling system

Adding engine coolant.

Check coolant level when the engine is cold as in-

dicated in the scheduled maintenance table, fol-

lowing the steps below:

Place the scooter on its centre stand and on flat

ground.


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- Undo the screw shown in the figure and remove

the expansion tank cap on RHS.

- Top up if the fluid level is near or below the MIN

level edge. The liquid level must always be be-

tween the MIN and MAX level.

-The coolant consists of an ethylene glycol and

corrosion inhibitor based 50% de-ionised water-

antifreeze solution mix.

CAUTION

DO NOT EXCEED THE MAX LEVEL WHEN FILLING SOTHAT COOLANT DOES NOT SPILL OVER THE EXPAN-SION TANK WHEN THE VEHICLE IS BEING USED.


SPECIAL AGIP PERMANENT fluidCoolant

Monoethylene glycol based antifreeze solution,

CUNA NC 956-16

Braking system

Level check

The front and rear brake fluid reservoirs are both

positioned on the handlebars. Proceed as follows:

- Rest the vehicle on its centre stand with the han-

dlebars perfectly horizontal;

- Check the fluid level through the sight glass

C. A certain lowering of the level is caused by

wear on the pads.

Top-up

Proceed as follows: Loosen the screw B and lift

the plastic cover A in order to access the brake

fluid reservoir. Loosen the two fixing screws and

remove the reservoir cover; top-up with the rec-

ommended fluid without exceeding the 'MAX.'

mark.


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This procedure applies to the rear brake pump top-

up operation; follow the same procedure for the

front brake pump.

Under standard climatic conditions, replace cool-

ant as indicated in the scheduled maintenance

table.

WARNING

ONLY USE DOT 4 CLASS BRAKE FLUIDS. BRAKING CIR-CUIT FLUIDS ARE HIGHLY CORROSIVE. MAKE SURETHAT IT DOES NOT COME INTO CONTACT WITH THEPAINTWORK.

CAUTION

AVOID CONTACT OF THE BRAKE FLUID WITH YOUREYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTALCONTACT, WASH WITH WATER.


AGIP BRAKE 4Brake fluid

FMVSS DOT4 Synthetic fluid

Headlight adjustment

Proceed as follows:

- Position the unloaded vehicle, in running order

and with the tyres inflated to the prescribed pres-

sure, onto a flat surface 10 m away from a half-lit

white screen; make sure the scooter axis is per-

pendicular to the screen;

- Remove the headlight assembly central cover.

- Turn on the headlight and check that the border

of the projected light beam on the screen is not

higher than 9/10 or lower than 7/10 f the height

from the ground to the centre of vehicle headlamp;

- Otherwise, adjust the headlight with the screws

A indicated in the figure

N.B.

THE ABOVE PROCEDURE COMPLIES WITH THE EURO-PEAN STANDARDS REGARDING MAXIMUM AND MINI-MUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATU-TORY REGULATIONS IN FORCE IN EVERY COUNTRY

WHERE THE VEHICLE IS USED.


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This section makes it possible to find what solutions to apply when troubleshooting.

For each failure, a list of the possible causes and pertaining operations is given.

Engine

Excessive oil consumption/Exhaust smoke

EXCESSIVE CONSUMPTIONPossible Cause Operation

Wrong valve adjustment Adjust the valve clearance properly

Overheated valves Remove the head and the valves, grind or replace the valves

Misshapen/worn valve seats Replace the head unit

Worn cylinder, Worn or broken piston rings Replace the piston cylinder assembly or piston rings

Worn or broken piston rings or piston rings that have not been

fitted properly

Replace the piston cylinder unit or just the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR LUBRICATION PRESSUREPossible Cause Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean theBy-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oi l pump components

Oil filter too dirty Replace the cartridge filterOil level too low Restore the level adding the recommended oil type

Transmission and brakes

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGEPossible Cause Operation

Faulty clutch Check that there is no grease on the masses. Check that the

clutch mass faying surface with the bell is mainly in the centrewith equivalent characteristics on the three masses. Check thatthe clutch casing is not scored or worn in an anomalous way

Insufficient braking

INEFFICIENT BRAKING SYSTEMPossible Cause Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs arenot worn, scored or warped. Check the correct level of fluid inthe pumps and change brake fluid if necessary. Check there isno air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Troubleshooting MP3 400 i.e.

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Possible Cause Operation

Brake disc slack or distorted Check the brake disc screws are locked; measure the axial shiftof the disc with a dial gauge and with wheel mounted on the

scooter.

Brakes overheating

BRAKES OVERHEATINGPossible Cause Operation

Defective plunger sliding Check calliper and replace any damaged part.

Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge anda wheel mounted on the vehicle to measure the axial deviation

of the disc.

Clogged compensation holes on the pump Clean carefully and blast with compressed air

Swollen or stuck rubber gaskets Replace gaskets.

Steering and suspensions

Heavy steering

STEERING HARDENINGPossible Cause Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-larities continue in turning the steering even after making theabove adjustments, check the seats in which the ball bearingsrotate: replace them if they are recessed or if the balls are flat-

tened.

Excessive steering play

EXCESSIVE STEERING CLEARANCEPossible Cause Operation

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-larities continue in turning the steering even after making theabove adjustments, check the seats in which the ball bearingsrotate: replace them if they are recessed or if the balls are flat-

tened.

Noisy suspension

NOISY SUSPENSIONPossible Cause Operation

Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the frontshock absorber; the condition of the ball bearings and relevantlock-nuts, the limit switch rubber buffers; and the movementbushings. In conclusion, check the tightening torque of the

wheel hub, the brake calliper, the shock absorber disc in theattachment to the hub and the steering tube.

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Suspension oil leakage

OILLEAKAGEFROMSUSPENSIONPossible Cause Operation

Faulty or broken seals Replace the shock absorber Check the condition of wear of thesteering covers and the adjustments.

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INDEX OF TOPICS

ELECTRICALSYSTEM ELE SYS

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MP3 400 i.e.

KEY

1. Injection ECU

2. Immobilizer aerial

3. Lambda sensor

4. Magneto flywheel

5. Voltage regulator

6. Engine stop switch

7. Radiator electric fan

8. Electric fan remote control

9. Main fuses

10. Socket 12V

11. Key switch contacts

12. Auxiliary fuses


14. Fuse

15. Battery

16. Starter motor

17. Starter remote control switch

18. Start-up enabling remote control switch

Electrical system MP3 400 i.e.

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19. Boot actuator

20. Saddle opening actuator

21. Saddle opening receiver

22. Starter button

23. Stop button on rear brake

24. Stop button on front brake

25. Turn indicator switch

26. Hazard button

27. Turn indicator control device and hazard

28. Pre-installation for anti-theft device

29. Helmet compartment light button

30. Helmet compartment light button31. Light switch

32. Headlight remote control

33. Helmet compartment internal light

34. Rear left light

A. Rear left turn indicator bulbs

B. Stop light bulb

C. Tail light bulb

35. License plate light

36. Rear right light

A. Tail light bulb

B. Stop light bulb

C. Rear right turn indicator bulbs

37. Front left turn indicator

38. Headlight

A. Tail light bulbs

B. Low-beam light bulb

C. High-beam light bulb

39. Front right turn indicator

40. Pressure sensor

41. Horn remote control

42. Horn

43. Horn button

44. Oil pressure sensor

45. Parking brake button

46. Coolant temperature sensor:

47. External temperature sensor

MP3 400 i.e. Electrical system

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48. Instrument panel

49. Parking control ECU

50. Brake calliper sensor

51. Geared motor

52. Fuel level transmitter

53. MODE button

54. Rider presence sensor

55. Locking/unlocking switch

56. Injection load remote control

57. Fuel pump

58. Fuel injector

59. Potentiometer60. Right wheel turning sensor

61. Left wheel turning sensor

62. HV coil

63. Diagnostics socket

64. Engine rpm sensor

MP3 400 i.e. RL

KEY

1. Instrument panel

2. Rear right turn indicator bulbs

3. Front right turn indicator bulbs


5. Front left turn indicator bulbs

6. Rear left turn indicator bulbs

7. Hazard button

8. Turn indicator control device with hazard


10. Headlight with 12V-55W twin-filament bulb

11.Front position light bulbs

12. License plate bulb

13. Tail light bulbs



16.Boot actuator

17.Light switch

18. Stop buttons


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19.Auxiliary fuses unit


21.Oil pressure sensor

22. Pressure sensor




26. MODE button

27. Diagnosis socket

28. Injection ECU

29. Fuel pump

30. Engine temperature sensor31. Fuel injector

32. HV coil



35. Lambda sensor

36. Right speed sensor

37. Left speed sensor

38. Potentiometer




42. Geared motor

43. Hand brake

44. Tilt locking/unlocking switches



47. Horn

48.Horn button


50. 12V - 10W stop light bulbs

51. Battery

52. Starter remote control

53.Starter motor


55.Starter button

56.Main fuses unit


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57. Magneto flywheel


59. Helmet compartment light switch

60. Boot light switch

61. Boot and helmet compartment light bulb

62. Socket 12V




Key

Ar: Orange Az: Sky Blue Bi: White Bl: Blue Gi: Yellow Gr:Grey

Ma:Brown Ne: Black Ro: Pink Rs: Red Ve: Green Vi: Purple

Components arrangement


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1 - Relays for lights / horn / injection load / electric

fan: remove the front shield to reach it.

2 - Auxiliary fuses: remove the footrest flap to

reach these fuses.


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3 /4 /19 - Electronic control unit for injection

(MIU) / Start-up relay / Start-up enabling switch

relay: remove the lid of the helmet compartment to

reach these relays.

N.B. when fitting the Start-up relay make sure to

connect the two "power" terminals correctly:

Battery Cable on terminal "B"

Starter motor cable on terminal "M"

5 /6 /10 - Fuel pump / Fuel level sensor / coil:

remove the chassis central cover to reach these

components.


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7 - Voltage regulator: remove the right side fairing

to reach them.

8 - Immobilizer aerial: remove the shield back plate

to reach it.

9 /18 - Saddle opening receiver/ Turn indicator

control device: to reach it, remove the left fairing.


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11 /12 - Diagnostics socket/ main fuses: these

components are found in the battery compartment.

13 - Lambda probe: The lambda probe is mounted

on the exhaust manifold.

14 - Engine oil pressure sensor: remove the ex-

haust end to reach it.

15 - Centralina comando stazionamento: per ac-

cedervi rimuovere il controscudo.


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16 - Rider presence sensor: open the saddle and

remove the cover to reach the rider presence sen-

sor.

17 - Coolant temperature sensor: remove the lid of

the helmet compartment and disconnect the con-

nector to reach it.

20 - Horn: remove the shield back plate lower side

to reach it.

21 - Geared motor assembly: remove the legshield

to reach it.

Conceptual diagrams

Ignition

MP3 400 i.e.


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KEY

1. Injection ECU


9. Main fuses


12. Auxiliary fuses

15. Battery


62. HV coil

MP3 400 i.e. RL

KEY

1. Instrument panel

19. Auxiliary fuses unit


28. Injection ECU

32. HV coil

33.Engine rpm sensor

49.Injection load remote control

51. Battery


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56. Main fuses unit


Battery recharge and startingMP3 400 i.e.

KEY

1. Injection ECU

4. Magneto flywheel



9. Main fuses


12. Auxiliary fuses

14. Fuse

15. Battery

16. Starter motor

17. Starter remote control switch


22. Starter button

23. Stop button on rear brake


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24. Stop button on front brake

34. Rear left light

B. Stop light bulb


B. Stop light bulb

MP3 400 i.e. RL

KEY

1. Instrument panel

18. Stop buttons


28.Injection ECU


50. 12V - 10W stop light bulbs

51. Battery

52. Starter remote control

53.Starter motor

54.Start-up enabling remote control switch

55. Starter button

56. Main fuses unit

57. Magneto flywheel



Level indicators and enable signals section

MP3 400 i.e.


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KEY

1. Injection ECU


3. Lambda sensor

9. Main fuses


12. Auxiliary fuses

15. Battery

44. Oil pressure sensor

46. Coolant temperature sensor:








58. Fuel injector

59. Potentiometer

60. Right wheel turning sensor


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61. Left wheel turning sensor


MP3 400 i.e. RL

KEY

1. Instrument panel


20.Fuel level transmitter


28. Injection ECU

29. Fuel pump

30.Engine temperature sensor

31. Fuel injector


35.Lambda sensor

36.Right speed sensor

37. Left speed sensor38. Potentiometer

39.Parking control ECU



44. Tilt locking/unlocking switches


51. Battery

56.Main fuses unit



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Devices and accessories

MP3 400 i.e.

KEY

1. Injection ECU



9. Main fuses

10. Socket 12V


12. Auxiliary fuses


15. Battery

19. Boot actuator






33. Helmet compartment internal light


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40. Pressure sensor


42. Horn

43. Horn button

45. Parking brake button



51. Geared motor

53. MODE button


55. Locking/unlocking switch

56. Injection load remote control57. Fuel pump

63. Diagnostics socket

MP3 400 i.e. RL


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KEY

1. Instrument panel



5. Front left turn indicator bulbs

6.Rear left turn indicator bulbs



16. Boot actuator


22. Pressure sensor


26. MODE button28. Injection ECU


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29.Fuel pump


42.Geared motor

43. Hand brake



47. Horn

48. Horn button

49.Injection load remote control

51.Battery

56.Main fuses unit

59. Helmet compartment light switch60. Boot light switch

61. Boot and helmet compartment light bulb

62.Socket 12V




Lights and turn indicators

MP3 400 i.e.


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KEY

9. Main fuses


12. Auxiliary fuses


15. Battery


26. Hazard button

27. Turn indicator control device and hazard

31. Light switch


34. Rear left light

A. Rear left turn indicator bulbs

C. Tail light bulb

35. License plate light


A. Tail light bulb

C. Rear right turn indicator bulbs

37. Front left turn indicator

38. Headlight


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A. Tail light bulbs

B. Low-beam light bulb

C. High-beam light bulb

39. Front right turn indicator



MP3 400 i.e. RL

KEY

1. Instrument panel




5.Front left turn indicator bulbs

6. Rear left turn indicator bulbs

7.Hazard button

8.Turn indicator control device with hazard

10. Headlight with 12V-55W twin-filament bulb

11.Front position light bulbs

12. License plate bulb

13. Tail light bulbs


17.Light switch


25.Key switch contacts

51. Battery

56.Main fuses unit

65.Key switch contacts

Checks and inspections

This section is devoted to the checks on the electrical system components.


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Immobiliser

The electronic ignition system is controlled by the

control unit with the integrated Immobilizer sys-

tem. The immobilizer is an anti-theft system that

allows the vehicle to be operated only when it is

started with coded keys recognised by the control

unit. The code is integrated in a transponder in the

key block. This allows the driver clear operation

without having to do anything other than just turn-

ing the key. The Immobilizer system consists of the

following components:

- an electronic control unit

- immobilizer aerial

- Master key with incorporated transponder (red

key)

- service key with incorporated transponder (black

key)

- HV coil

- diagnosis LED

The diagnosis LED also works as a theft-deterrent

blinker. This function is activated every time the

ignition switch is turned to the "OFF" position, or

the emergency stop switch is turned to the "OFF"

position. It remains activated for 48 hours in order

not to affect the battery charge. When the ignition

switch is turned to the "ON" position, the theft-de-

terrent blinker function is deactivated. Subse-

quently, a flash confirms the switching to the "ON"status. The duration of the flash depends on the

programming of the electronic control unit If the

LED is off regardless of the position of the ignition-

key switch and/or the instrument panel is not initi-

ated, check if:

there is battery voltage

fuses 1,7,10 are in working order

there is power to the control unit as

specified below:


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Remove the connector support bracket shown in

the photograph and disconnect the connector from

the control unit. Check the following conditions:

With the key switch set to OFF:

if there is battery voltage between ter-

minals 6-26 and terminal 6-chassis

ground (fixed power supply). If there is

no voltage, check that fuse 1 and its

cable harness for the MP3 400 i.e. ver-

sion and fuse 6 and its cable harness

for the MP3 400 i.e. RL version are in

working order.

With the key switch in the OFF position:

there is battery voltage between termi-

nals 5-26 and terminal 5-frame earth

(fixed power supply). If there is no volt-

age, check the key switch contacts,

that fuse no. 10 and its cable are in

working order.

There is continuity between terminals

12-18 with the emergency cut-off

switch in the RUN position. If there is

no continuity check the contacts of the

switch.

If no faults are found, replace the electronic control

unit.

After removing the shield back plate, remove the

electrical connection from the aerial as shown in

the picture.


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Remove the protective base from the connector.

With the ignition key in ON check if there is battery

voltage between the Red-White and Black cables

for the MP3 400 i.e. version and between the Red-

Black and Orange cables for the MP3 400 i.e. RLversion.

With MIU connector disconnected, check the con-

tinuity between the Orange-White cable and pin 7

of the interface wiring.

Specific tooling020481YControl unit interface wiring

020331YDigital multimeter

Virgin circuit

When the ignition system is not encrypted, any key will start the engine but limited to 2000 rpm. The

keys can only be recognised if the control unit has been programmed properly. The data storage pro-

cedure for a previously not programmed control unit provides for the recognition of the master as the

first key to be stored to memory: this becomes particularly important because it is the only key that


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enables the control unit to be wiped clean and reprogrammed for the memorisation of the service keys.

The master and service keys must be used to code the system as follows:

- Insert the Master key, turn it to ON and keep this position for two seconds (limit values 1 to 3

seconds).

- Insert the service key and turn it to ON for 2 seconds.

- If you have copies of the key, repeat the operation with each key.

- Insert the MASTER key again and turn it to ON for 2 seconds.

The maximum time to change keys is 10 seconds.

A maximum of 7 service keys can be programmed at one time.

It is essential to adhere to the times and the procedure. If you do not, start again from the beginning.

Once the system has been programmed, the master key transponder is strictly matched with the control

unit. With this link established, it is now possible to encode new service keys, in the event of losses,replacements, etc. Each new programming deletes the previous one; to add or delete a key it is therefore

necessary to repeat the procedure using all the keys that you intend to keep in use. If a service key

becomes uncoded, the efficiency of the high voltage circuit shielding must be thoroughly inspected: In

any case it is advisable to use resistive spark plugs.

Characteristic

MASTER key:

RED KEY

SERVICE key.

BLACK KEY

Diagnostic codes

The Immobilizer system is tested each time the

key switch is turned from OFF to ON. During

this diagnosis phase a number of control unit sta-

tuses can be identified and various light codes

displayed. Regardless of the code transmitted, ifat the end of the diagnosis the LED remains off

permanently, the ignition is enabled. If, however,

the LED remains on permanently, it means the ig-

nition is inhibited:

1. Previously unused control unit - key inser-

ted: a single 2 second flash is displayed, after

which the LED remains off permanently. The keys

can be stored to memory, the vehicle can be star-


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ted but with a limitation imposed on the number of

revs.

2. Previously unused control unit - transpond-

er absent or cannot be used: The LED is per-

manently ON; in this condition, no operations are

possible, not even starting the vehicle.

3. Programmed control unit - service key in-

serted (normal conditions of use): a single 0.7-

second flash is displayed, after which the LED

remains off steadily. The engine can be started.

4. Programmed control unit - Master key inser-

ted: a 0.7-sec flash is displayed followed by theLED remaining off for 2 sec and then by short 0.46-

sec flashes the same number of times as there are

keys stored in the memory including the Master

key. When the diagnosis has been completed, the

LED remains permanently OFF. The engine can

be started.

5.Programmed control unit - fault detected: a light code is displayed according to the fault detected,

after which the LED remains on steadily. The engine cannot be started. The codes that can be trans-mitted are:

1-flash code

2-flash code

3-flash code

Diagnostic code - 1 flash

A one-flash code indicates a system where the se-

rial line is not present or is not detected. Check the

Immobilizer aerial wiring and change it if necessa-

ry.


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Diagnostic code - 2 flashes

A two-flash code shows a system where the con-

trol unit does not show the transponder signal. This

might depend on the inefficiency of the immobiliser

aerial or the transponder.

Turn the switch to ON using several keys: if the

code is repeated even with the Master key, check

the aerial wiring and change it if necessary. If this

is not the case, replace the defective key and/or

reprogram the control unit. Replace the control unit

if the problem continues.

Diagnostic code - 3 flashes

A three-flash code indicates a system where the

control unit does not recognise the key. Turn the

switch to ON using several keys: if the error code

is repeated even with the Master key, replace the

control unit. If this is not the case, reprogram the

decoder.

Battery recharge circuit

The recharge circuit is provided with a three-phase generator with permanent magneto flywheel.

The generator is directly connected to the voltage regulator.

This, in its turn, is connected directly to the ground and the battery positive terminal passing through

the 30A protective fuse.

The three-phase generator provides good recharge power and at low revs, a good compromise is ach-

ieved between generated power and idle stability.

Stator check

Checking the stator windings

WARNING

THIS CHECK-UP CAN BE MADE WITH THE STATOR PROPERLY INSTALLED.

1) Remove the right side panel.

2) Disconnect the connector between stator and regulator with the three yellow cables as shown in the

photograph.


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3) Measure the resistance between each of the yellow terminals and the other two.


Resistance:

0.2 - 1

4) Check that there is insulation between the each

yellow cable and the ground.

5) If values are incorrect, replace the stator.

Recharge system voltage check

Look for any leakage

1) Access the battery by removing its cover under the saddle.

2) Check that the battery does not show signs of losing fluid before checking the output voltage.

3) Turn the ignition key to position OFF, connect the terminals of the tester between the negative pole

(-) of the battery and the black cable and only then disconnect the black cable from the negative pole

(-) of the battery.

4) With the ignition key always at OFF, the reading indicated by the ammeter must be 0.5 mA.

Charging current check

WARNING

BEFORE CARRYING OUT THE CHECK, MAKE SURE THAT THE BATTERY IS IN GOOD WORK-ING ORDER.

1) Park the vehicle on its centre stand

2) With the battery correctly connected to the circuit, place the multimeter leads between the battery

terminals..

3) Turn on the engine, increase the engine rpm and, at the same time, measure the voltage.


Voltage ranging between 14.0 and 15.0V at 5000 rpm.

Maximum current output check.

- With the engine off and the panel at ON with the lights on, allow the battery voltage to stop at 12V.

- Connect ammeter pliers to the 2 recharge positive poles in output from the regulator.

- Start the engine and rev it up to a high engine speed while reading the value on the pincer.

With an efficient battery a value must be detected: > 20A


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VOLTAGE REGULATOR/RECTIFIERSpecification Desc./Quantity

Type Non-adjustable three-phase transistor

Voltage 14 15V at 5000 rpm with lights off

Fuses

The electrical system has twelve fuses divided into

two fuse boxes to protect the different installation

circuits. One of them is inside the battery compart-

ment A and the other is at the internal side of

the right footrest B.To have access, loosen the

screw C and remove the plastic cover. The chart

shows the position and characteristics of the fuses

in the vehicle.

CAUTION

BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVETHE FAILURE THAT CAUSED IT TO BLOW. NEVER TRYTO REPLACE THE FUSE WITH ANY OTHER MATERIAL(E.G., A PIECE OF ELECTRIC WIRE).


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The fuse No. 13 is located on the start-up remote

control switch.

FUSE TABLESpecification Desc./Quantity

1 Fuse No. 1 Capacity: 7.5 AProtected circuits:Injection ECU battery power

2 Fuse No. 2 Capacity: 15 AProtected circuits:Battery-powered injection loads,

electrical fan

3 Fuse No. 3 Capacity: 15 AProtected circuits:Battery power for saddle opening re-ceiver, case lighting, headlight relay, turn indicator con-

trol device

4 Fuse No. 4 Capacity: 20AProtected circuits:battery-powered ECU for parking

control

5 Fuse No. 5 Capacity: 20AProtected circuits:battery-powered fuse No. 7, live

fuses No. 8 - 9 - 10 - 11

6 Fuse No. 6 Capacity: 15 AProtected circuits:L.V. socket.

7 Fuse No. 7 Capacity: 7.5 A

Protected circuits:Battery-powered instrument panel8 Fuse No. 8 Capacity: 10A

Protected circuits:Live stop, start-up and start-up ena-bling lights.

9 Fuse No. 9 Capacity: 7.5 AProtected circuits:live passing and horn

10 Fuse No. 10 Capacity: 7.5AProtected circuits:Live injection ECU, immobilizer aer-

ial, electric fan remote control, injection load remotecontrol

11 Fuse No. 11 Capacity: 7.5AProtected circuits:Live parking control ECU, pre-instal-lation for anti-theft device, instrument panel, headlight

remote control, horn remote control

12 Fuse No. 12 Capacity: 7.5A

Protected circuits:Live turn indicator control, saddleopening switch, tail lights, panel lighting


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LIGHT BULBS TABLESpecification Desc./Quantity

1 Helmet compartment light bulb Type: Incandescent (SV 8.5)Power: 12V - 5W

Quantity: 12 High/low beam light bulb Type: Halogen (H1)

Power: 12V - 55WQuantity: 2

3 Front tail light bulb Type: Incandescent (W2.1x9.5d)Power: 12V-3W

Quantity: 2

4 Stop light bulb Type: Incandescent (BA 15s)Power: 12V - 10W

Quantity: 2

5 License plate bulb Type: Incandescent (W2.1x9.5d)Power: 12V - 5W

Quantity: 1

6 Rear tail light bulb Type: Incandescent (W2.1x9.5d)Power: 12V - 5W

Quantity: 27 Rear turn indicator bulb Type: Incandescent (W2.1x9.5d)Power: 12V - 5W

Quantity: 4

8 Font turn indicator bulb Type: Incandescent (BAU 15s)Power: 12V-10W

Quantity: 2

Dashboard


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A = Led immobilizer / anti-theft device

B= Speedometer with twin scale (km/h and mph)

C = CLOCK switch

D = Digital display

E = Front suspension locking system warning light

(if available)

F = SET switch

G = Rpm indicator

H = Fuel gauge

I = Warning light for helmet compartment courtesy

light on

L = Engine control telltale light and injection sys-tem failure warning light

M = Low fuel warning light

N = Engine stop warning light

O= Turn indicator warning light

P = Low oil pressure warning light

Q = Front suspension locking system failure warn-

ing light (if available)

R = Warning light for parking brake engaged

S = High-beam warning light

A = Total odometer gauge

B = BELT maintenance icon

C = SERVICE maintenance icon

D = Engine coolant temperature indicator

E = Trip odometer (A-B) and ambient temperature gauge (selected with the MODE button)

F = TIME-DATE indicator

G = Low fuel warning light

H = Trip odometer gauge (B)

I = Trip odometer gauge (A)

L = Kilometre - mile indicator

Sealed battery

If the vehicle is provided with a sealed battery, the only maintenance required is checking its charge

and recharging, when necessary.

These operations should be carried out before delivering the vehicle, and on a six-month basis while

the vehicle is stored in open circuit.


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Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if

required, before storing the vehicle and, afterwards, every six months.

INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

1) Voltage check up

Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.

- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

- Constant voltage charge equal to 14.40 14.70V

- Initial charge voltage equal to 0.3 0.5 for Nominal capacity

- Charge time:

10 to 12 h recommendedMinimum 6 h

Maximum 24 h

3) Constant current battery charge mode

- Charge current equal to 1/10 of the battery rated capacity

- Charge time: Maximum 5 h

Connectors

INJECTION ELECTRONIC CONTROL UNIT

CONNECTOR

1. Injection telltale light LED (Brown-Black)

2. Rpm indicator on instrument panel (Yellow)

3. CAN "L" Line (White-Blue)

4. Lambda probe (-) (White-Green)

5. Live supply (Red-White)

6. Battery-powered (Orange-Black)

7. Immobilizer aerial (Orange-White)8. Electric fan remote control (Blue-Yellow)

9. Coolant temperature sensor (Sky blue-Green)

10. CAN "H" Line (Pink-White)

11. Lambda probe (+) (Sky blue-Black)

12. Engine stop switch (Green-Black)

13. Engine rpm sensor positive (Red)

14. Fuel injector (Red-Yellow)

15. Engine rpm sensor negative (Brown)

16. Diagnosis (Purple-White)


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17. Immobilizer LED (Red-Green)

18. Engine stop switch, coolant temperature sen-

sor (Grey-Green)

19. Not connected

20. Injection load remote control (Black-Purple)

21. Not connected

22. HV coil (Pink-Black)

23. Not connected

24. Start-up enabling switch (Orange-Blue)

25. Not connected

26. Ground lead (Black)

PICK-UP CONNECTOR1. Injection ECU (Red)

2. Injection ECU (Brown)

VOLTAGE REGULATOR CONNECTOR1. Battery positive (Red-Black)


3. Battery positive (Red-Black)


SADDLE OPENING RECEIVER CONNECTOR1. Aerial (Purple)

2. Saddle opening actuator (Yellow-Grey)

3. Reset (Blue-Black)

4. Battery-powered (Blue)

5. Not connected

6. Live supply (Yellow-Black)

7. Ground lead

8. Not connected

9. Not connected


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10. Boot actuator (Yellow)

11. Channels 1/3 selector (Green-Blue)

12. Alarm code (Orange-Black)

TURN INDICATOR CONTROL DEVICE CON-

NECTOR

1. Hazard button (Brown)

2. Left Switch (White-Pink)

3. RHS Switch (Blue-Black)

4. Left turn indicators (Pink)

5. Right turn indicators (White-Blue)


7. Not connected8. Live supply (Yellow-Black)


10. Not connected

11. Not connected

12. Not connected

HV COIL CONNECTOR

1. Injection load remote control (Black-Green)

2. Injection ECU (Pink-Black) for the MP3 400 i.e.version and (Red-Black) for the MP3 400 i.e. RL

version.

ANTI-THEFT DEVICE PRE-INSTALLATION

CONNECTOR

1. Left turn indicators (Pink)2. Right turn indicators (White-Blue)



5. Live supply (Yellow-Red)

6. Helmet compartment lighting warning light

(Blue-Black)

7. Channels 1/3 selector (Green-Blue)

8. Alarm code (Orange-Black)


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FUEL PUMP CONNECTOR

1. Injection load remote control (Black-Green)

2. Not connected

3. Not connected


5. Not connected

INSTRUMENT PANEL CONNECTOR "A"

1. Not connected

2. Not connected

3. Not connected

4. Not connected

5. Instrument panel lighting (Yellow-Black)

6. Battery-powered (Red-Blue)

7. Not connected

8. Not connected

9. Not connected

10. Not connected


12. Live supply (Yellow-Red)

INSTRUMENT PANEL CONNECTOR "B"

1. Scooter speed signal (Sky blue)

2. Fuel level indicator (White-Green)

3. Water temperature sensor (Sky blue-Black)

4. Water temperature sensor ground lead (Brown-

White)

5. MODE remote button (Green)

6. Oil pressure sensor (Pink-White)

7. Left turn indicator warning light (Pink)

8. Right turn indicator warning light (White-Blue)

9. High-beam warning light (Purple)

10. Boot open warning light (Blue-Black)

11. Rpm sensor (-)

12. Ambient temperature sensor (Yellow-Blue)

13. Ambient temperature sensor ground (White-

Yellow)


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14. Engine disabled warning light (Orange-Blue)

15. Immobilizer warning light (Red-Green)

16. Engine check warning light (Brown-Black)

17. Parking brake warning light (Yellow-Grey)

18. Tilt locking activated warning light (Pink-Black)

19. Tilt locking system failure warning light (Grey-

Black)

20. Live supply from the parking control ECU (Yel-

low-Green)

PARKING CONTROL ECU CONNECTOR

1A. Potentiometer power supply (Orange-Blue)

2A. CAN "L" Line (White-Blue)3A. Warning light power supply (Yellow-Green)

4A. Tilt locking activated warning light (Pink-Black)

5A. Tilt locking system failure warning light (Grey-

Black)

6A. Headlight remote control (White-Black)

7A. Potentiometer ground lead, rpm sensor, rider

presence sensor (Yellow)

8A. Ground lead (Black)

1B. Live supply (Yellow-Red)

2B. CAN "H" Line (Pink-White)

3B. Left wheel turning sensor (Green)

4B. Right wheel turning sensor (Red)

5B. Potentiometer signal (Green-Blue)

6B. Locking/unlocking switch (Green-Grey)

7B. Horn remote control for alarms (White)

8B. Geared motor (White-Red)

1C. Battery powered (Blue-Red)

2C. Diagnosis (Purple-White)

3C. Locking/unlocking switch (Yellow-Blue)

4C. Calliper sensor (Brown)

5C. Locking/unlocking switch (Purple-Black)

6C. Rider presence sensor (Purple)

7C. Scooter speed signal (Sky blue)

8C. Geared motor (Blue)


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Remote seat opening

Zeroing

- Remove the left side fairing to access the saddle

opening receiver control unit indicated in the pho-

tograph

- Remove the metal terminal and connect it to a

good earth point, or to terminal 7 (black), for at

least 10 seconds.

- In this operation all the remote controls stored in

the control unit will be deleted.

WARNING

THE CONTROL UNIT CAN PROGRAMME UP TO 8 REMOTECONTROLS.

Programming

Follow these steps to program the remote controls:

1. Insert the remote control key to be programmed in the steering lock key block.

2. Turn the key to ON, press the button on the remote control, release the button, then turn the key

back to OFF within four seconds of turning ON.

3. Wait 1 to 8 seconds.

4. Repeat steps 2 and 3 four more times without removing the key.

The control unit confirms the programming has been successful by opening the saddle.

WARNING

TO STORE THE OTHER REMOTE CONTROLS TO MEMORY (8 MAXIMUM) YOU NEED TO RE-PEAT THE WHOLE PROCEDURE AGAIN. FAILURE TO CARRY OUT THESE OPERATIONSWITHIN THE INDICATED TIMES WILL RESULT IN THE AUTOMATIC CANCELLATION OF THEPROCESS FOR PROGRAMMING THE REMOTE-CONTROLLED KEYS.

WARNING

AVOID PRESSING THE REMOTE CONTROL BUTTON MORE THAN ONCE WHEN FAR AWAYFROM THE SCOOTER. THE SYNCHRONISM BETWEEN THE REMOTE CONTROL AND THE RE-


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Documents

Manual MP3 400